Multi-stage modular rotary internal combustion engine

ABSTRACT

This Three-Stage Rotary Internal Combustion Engine has a Compressor Unit feeding compressed air to a Combustor Unit for further compression. It has a fuel injection and ignites at a high degree of compression and is driven by expansion of the resulting combustion gases. The Afterburner Unit that receives the combustion gases and scavenged air from the Combustor Unit for secondary combustion, additional work, and exhaust. Each Unit consists of a cylindrical Rotor, mounted in an eccentric position, connected to each other, turning unidirectional. Inside each Rotor are multiple Vanes that are slidable, movable within the slots of the Rotor. Said Vanes are provided with half-round knobs on opposite sides, aligned with the top end surface, that slide and rotate in hemispherical grooves acting as a raceway on the interior side-walls of the housing, enabling the Vanes to maintain contact with the interior periphery insensitive to pressures and speed.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

FEDERALLY SPONSORED RESEARCH

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SEQUENCE LISTING OR PROGRAM

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BACKGROUND OF THE INVENTION—FIELD OF THE INVENTION

This invention relates to a Three-Stage Rotary Internal Combustion Engine of the Vane type, which includes a Compressor Unit, Combustor Unit and Afterburner Unit.

SUMMARY

A Three-Stage Rotary Internal Combustion Engine used for a prime mover, is disclosed having a Compressor Unit feeding compressed air to a Combustor Unit for further compression, having a means of fuel injection and igniting at a high degree of compression and being driven by expansion of the resulting combustion gases, an Afterburner Unit receiving the combustion gases and scavenged air from the Combustor Unit for further lean burning, expansion, additional work and exhaust. Each Unit consists of a cylindrical Rotor that has a shaft on both ends. The Combustor Unit shaft is connected to the Compressor Unit shaft as well as the Afterburner Unit shaft by means of splines. It turns unidirectional and has output ends for continuously transmitting power. Said rotating shaft of the cylindrical Rotor is mounted in an eccentric position within the interior of the Housing, supported by the Housing interior carrying walls. Inside each Rotor are multiple Vanes that are slidable, movable within the slots of the Rotor.

The Combustor Unit and Afterburner Unit are provided with four Vanes each. The Compressor Unit with eight dual pressure balanced Vanes.

Said Vanes are provided with half-round knobs on opposite sides, aligned with the top end surface. Said half-round knobs fit in, and slide in hemispherical grooves that act as a raceway on the interior side-walls of the housing. The grooves follow the contour of the interior periphery of the Housing, enabling the Vanes to maintain contact with the interior wall.

The Combustor Unit has four chambers, an inlet and exhaust chamber, a compression chamber, and an expansion chamber to create power. The Unit is defined by two sealing blades, the interior carrying sidewalls of the Housing, the peripheral wall of the interior Housing, the outside cylindrical surface of the Rotor. The Compressor and Afterburner have similarly four chambers formed in an identical configuration.

The Compressor, Combustor and Afterburner Units are assembled and secured by means of fasteners, while the Rotor shafts are interlinked by splines to form a common shaft turning unidirectional at the same speed. The Engine provides four compression, ignition, and expansion power cycles per revolution including exhaust. The Engine is adaptable to a variety of operating conditions and may be operated either as a Diesel System with a high over-all volume ratio and compression ignition, or at a lower compression ratio with internal spark ignition and fuel injection for both systems.

BACKGROUND OF INVENTION

This invention relates to a Three-Stage Modular Rotary Internal Combustion Engine, which consists out of a Compressor Unit, Combustor Unit and Afterburner Unit. Each Unit consists out of a Housing with a bore and a cylindrical Rotor with a shaft that transfers the rotating motion of the Rotor. The Rotor shafts are mounted in an eccentric position and supported by the interior carrying sidewalls of said Housing. Said Rotor is provided with a plurality of Vanes inserted in radial slots, ninety degrees apart, and are slidable and movable in said slots.

In the basic configuration, the Combustor and Afterburner Units each have four Vanes, while the Compressor Unit has four dual pressure balanced Vanes.

The Rotary Engine with Vanes has many variations. This invention is directed to a Rotary Vane Engine with an eccentric Rotor and Vanes, ninety degrees apart. The main features are as follows:

The Housing can have a cylindrical bore, (or oval, elliptical or any other curvilinear shape even epitrochoid), free of abrupt bumps, thus avoiding seal shock and wear and chatter marks on the bore surfaces. A cylindrical Rotor, except for the epitrochoid configuration, is mounted in an eccentric position with respect to the Housing bore and supported by the interior Housing carrying walls. Hemispherical concentric grooves, aligned with the interior Housing periphery, are provided on opposite side walls. The grooves act as a guiding track for said Vanes, that are provided with half-round knobs on opposite sides, aligned with the top surface of the Vane. The cylindrical Rotors are provided with radial slots to allow said Vanes to slide in and out radially, when the Rotor is making its spinning motion. Henceforth said Vanes are retained, guided and sliding along the Housing side walls and Housing interior periphery. Although, the Rotary Vane Engine has not been widely used due to some technical deficiencies, the approach provided in this Engine design could result in a simple, easily manufacturable, reliable, efficient and clean burning Internal Combustion Engine. Furthermore, said slidable and movable Vanes, guided and suspended in the grooves of the side-walls and in continuous contact with the interior Housing periphery, do not require the use of springs, cams or any other aids.

The power output is realized by the function of the Vanes sliding around the periphery of the Housing bore and reciprocating in and out of the Rotor slots. Resulting in a spin of the Rotor which is mounted in an eccentric position. The four combustion processes per revolution, results in a reduced differential pressure between Combustion, Expansion, and Compression chambers, therefore a high sealing requirement of the Vanes and the Housing side walls and periphery of the bore is not required which reduces friction. In addition any gas blowback goes to the Afterburner for re-burning. The only important sealing area is at the bottom of the Vanes due to exposure of lubricating and cooling oil flowing through the center hollow core of the Shaft and Rotor for a “WET” Vane configuration.

It is feasible to have a “DRY” Vane configuration as well comprising dual balanced Vanes inserted into blind slots, thus oil seals won't be necessary, however lubrication for the Vanes is always provided through lubrication holes. The material used for this engine's Housing, Rotor, Vanes and Fasteners is high-strength steel. However, the Dual pressure balanced Vanes for the Compressor Unit could be made of aluminum-bronze or an equivalent material.

SUMMARY OF THE INVENTION

It is the primary objective of this invention to provide a Multi-Stage Modular Rotary Internal Combustion Engine of the Vane type, that is simple in construction, robust in design, easy to manufacture, reliable in operation, has a high power output, compact size and is clean burning with reduced harmful emissions. Another object of the present invention is to provide water cooling of the Housing Modules and oil cooling and lubrication of moving parts.

The objects of this invention are realized by the following the technical solutions. According to the invention a Multi-Stage Rotary Internal Combustion Engine with permanently guided Vanes is presented, consisting out of a Compressor Unit providing scavenge and super charged air, a Combustor Unit incorporating a compressing portion, a working and expansion portion, an Afterburner Unit comprising an expansion and exhaust portion, an ignition system, a lubricating system, and a cooling system. Characterized as follows:

A. The working portion comprises at least a Compressor Unit, a Combustor Unit and an Afterburner Unit. An output Rotor shaft consists of a Combustor Rotor shaft linked with splines to, and driving a Compressor Rotor shaft. An Afterburner Rotor shaft is linked by splines to the Combustor shaft. Each cylindrical Rotor is provided with a plurality of radial slots. Four single Vanes are inserted in the Combustor and Afterburner Rotors. Four double Vanes are inserted in the cylindrical Rotor slots of the Compressor Unit. Said Vanes are sliding in and out the cylindrical Rotor radial slots and are provided with half round knobs at opposite sides at the top, aligned with the top surface, resulting in a vane, guided and suspended in the hemispherical grooves in both interior side walls of the Housing. This configuration reduces bending stresses of said Vanes. Said Rotor shafts are provided with a hollow core to allow for flow of cooling and lubrication oil for the Vanes.

B. The Compressor entity consists of the Housing with a cylindrical bore, and a cylindrical Rotor with a splined hollow core shaft, which is mounted in an eccentric position within the Housing and supported by the interior carrying walls. Said Rotor has eight radial blind slots, ninety degrees apart, in which eight Vanes are inserted. Said Vanes are provided with half round knobs on opposite sides at the top, aligned with the top surface, resulting in a vane, guided and suspended in the hemispherical grooves in both interior side-walls of the Housing.

The Rotor, rotates about its axis, the Vanes moving in and out the slots thus forming induction and compression chambers within the Housing interior side walls, the interior periphery and the outside surface of the cylindrical Rotor.

An inlet port in the Housing interior peripheral wall is provided on the upstream side in the induction chamber. An outlet port of the compressing portion is placed on the downstream side in the Housing peripheral wall leading to the inlet port of the Combustor Unit.

C. Said Combustor Unit, comprises a Housing with a cylindrical Bore (or other smoothly curvilinear shaped bore and side-walls), a splined hollow core shaft with a cylindrical rotor, placed in an eccentric position that is supported by the carrying walls of the Housing. Said Rotor has four radially oriented through slots, ninety degrees apart, in which four slidable and movable Vanes are inserted. Said Vanes are provided with half round knobs on opposite sides at the top, aligned with the top surface, resulting in a vane that is guided and suspended in the hemispherical grooves in both interior side walls of the Housing.

An inlet passage, linked to the Compressor, is installed in the interior wall of the Housing for the entrance of pre-compressed air for further compression, ignition, combustion and expansion. Scavenge air aides in expelling residual exhaust gases.

An exhaust outlet port is installed in the working portion of the Housing, which is located in the space surrounded by the Housing peripheral wall, the outside surface of the cylindrical Rotor, the two Vanes and the interior side walls of the Housing. The expanding gases are moved in the direction of the rotation to the outlet port, passed through the transfer line to the inlet port of the Afterburner.

Two spark plugs and two fuel injectors used in the ignition system of the engine are placed in the peripheral wall at the point of the highest compression. The expanding gases move the vanes in the direction of the exhaust port, thus spinning the rotor and shaft. The compression stroke in the Combustor is equivalent to ninety degrees, the expansion stroke is one hundred and fifty degrees, adding to the efficiency of the Engine's operating cycle and increasing energy utilization.

D. The aforementioned Afterburner entity comprises a Housing with a cylindrical bore (or other smoothly curvilinear shaped configuration), a splined hollow core shaft with a cylindrical rotor, placed in an eccentric position that is supported by the carrying walls of the Housing. Said Rotor has four radially oriented through slots, ninety degrees apart, in which four slidable and movable Vanes are inserted. Said Vanes are provided with half round knobs on opposite sides at the top, aligned with the top surface, resulting in a vane, guided and suspended in the hemispherical grooves in both interior side-walls of the Housing.

The hollow core in the center of the shaft allows for lubrication and cooling oil of the movable and slidable vanes. The exhaust gases and scavenge air from the Combustor Unit enter the Afterburner through an inlet passage, located in the Housing's interior peripheral wall. Two Glow Plugs ignite fugitive hydrocarbons used for afterburning.

The Glow Plugs are installed on the interior peripheral wall of the Housing, in a position adjacent to the upstream side in the direction of rotation of the working portion of the chamber.

The interior peripheral wall of the Housing is provided with an outlet port to expel afterburning gases. An optional water injection system can be incorporated to achieve additional power, reduce exhaust pollution while cooling the vanes on the Rotor.

The operating Volume formed by the Housing interior peripheral walls, the cylindrical Rotor's external surface, the Housing side walls and the two Vanes is greater than the corresponding volume of the working portion of the Compressor since the operating volume in the Afterburner consists of exhaust gases and scavenge air from the Combustor.

The present invention has the following advantages because of the features described above:

1. Since the Engine has three stages, a Compressor to supercharge the air for work and scavenge in the Combustor; a Combustor with a larger expansion than compression stroke; and an Afterburner to complete the lean burning process of the Combustor exhaust gases; it achieves improved utilization of energy.

2. Since the eccentric Rotors and shafts are supported on opposite sides by the interior carrying walls of the Housing and the Vanes are sliding and moving radially in slots of the Rotor and are guided and supported at the top end in the hemispherical grooves of the interior side-walls of the Housing, bending and friction forces between Vanes and Rotor slots are reduced.

3. Since the shafts of the eccentric Rotors have a hollow core and are interconnected by splines and communicate with each other, oil for lubrication and cooling is easily accommodated and reliability is increased.

4. Since during afterburning of the exhaust gases, gas leaks and blowbacks from the Combustor are collected in the Afterburner for re-burning by means of glow plugs, raising the exhaust gas temperature, water could be injected into the exhaust gases to achieve additional power for efficiency and to reduce exhaust pollutants.

5. Since for small Engines simplicity and weight are important, the afterburner could be omitted, and a Glow plug could be placed in the exhaust channel of the Combustor.

DESCRIPTION OF THE DRAWINGS

The present invention is illustrated with drawings of the preferred embodiment.

Following is a brief description of the drawings:

FIG. 1 is an external configuration of an embodiment according to the invention.

FIG. 2 is a cross-sectional drawing of FIG. 1, exhibiting the combined Modules of Compressor, Combustor and Afterburner interconnected by splines for the Rotor shafts and secured by means of bolts and nuts for the center Split Housings and provided with metallic spring seals at the interfaces.

FIG. 2A is a schematic, showing the working procedure of the embodiment of this invention, and the sequence of Operation of the Compressor, Combustor and Afterburner Units, including Vane positions with regard to the inlet port, gas transfer and exhaust gas port locations.

FIG. 3 is a cross-section of the Combustor with a cylindrical bore and “wet” Vanes. The bottom sides of the Vanes are in contact with lubrication and cooling oil flowing through the hollow core of the rotor and shaft.

FIG. 3A is a cross-section of the Combustor partly oval with a flat surface at the bottom side to minimize exhaust gases entering the compression chamber. The cylinder bore can be any smooth curvilinear shape to achieve the desired results.

FIG. 3B is a cross-section of the Combustor with dual wet Vanes, without Vane side seals.

FIG. 3C is a cross-section of the Combustor configured with dual pressure balanced Vanes. No seals are required.

FIG. 4 is a cross-section of the Compressor with a cylindrical bore and dual pressure balanced “Sealless” Vanes.

FIG. 5 is a cross-section of the Afterburner with a cylindrical bore and “Wet” Vanes.

FIG. 5A is a cross section of the Afterburner with a semi-elliptical shaped bore towards the exhaust port in order to obtain extra power.

FIG. 5B is a cross-section of the Afterburner configuration with dual pressure-balanced Vanes, water-cooling injection and lubrication.

FIG. 6 and FIG. 7 are a typical view and cross-section of the Combustor cylindrical Rotor, and slots with rounded ends and flat sided surfaces. The cylindrical rotor for the Afterburner is similar to the rotor of the Combustor. The Compressor has a rotor with dual blind slots without cooling passages.

FIG. 8 is a one-piece configuration of a typical Vane with half-rounded knobs on opposite sides aligned with the top surface, flat side walls and half-rounded or flat end walls.

FIG. 9 is a Vane configuration with separate knobs and pins.

DESCRIPTION OF THE EMBODIMENT

The Multi-Stage Modular Rotary Internal Combustion Engine as exhibited in FIG. 1 and FIG. 2 comprises a Compressor Unit, a Combustor Unit and an Afterburner Unit combined and secured by means of bolts and nuts to form one assembled Module. Several modules could be combined in series or in a parallel configuration.

For the sake of illustrating the invention clearly, external apparatus such as fuel injection and ignition system, water cooling radiator and pump, oil lubrication pump system, starting system and external piping are all omitted. The primary objective of this invention is to illustrate the operation of the embodiment of this Multi-Stage Modular Rotary Internal Combustion Vane Engine system, which is different from existing rotary engine systems. With reference to FIG. 2 and FIG. 4, the Compressor unit comprises a hollow core shaft with splines on opposite sides, a cylindrical Rotor 11, provided with eight radial blind slots, in which eight slidable and movable Vanes 13 provided with half round knobs on opposite sides, aligned with the top surface, are inserted. Shown in FIG. 8 and FIG. 9. The Rotor, with the Vanes inserted in the slots, is assembled in a cylindrical Housing 15 and 17 with the Rotor shaft mounted in an eccentric position within the housing's interior, and supported by the carrying walls of the Housing 15 and 17. The Vanes' knobs are engaged in the hemispherical grooves of the interior side walls of the Housing halves. Concurrently the Housing Halves 15 and 17 are secured by bolts 19 and nuts 9 while at the interface a circular spring-loaded metallic face seal is clamped to ascertain a leak proof and structurally sound connection. However, it is not required having two Housing halves, one Housing could have a bore while the other Housing could be a cover as long as the hemi-spherical grooves are provided on opposite side walls to retain the Vanes' half-rounded knobs, what enables the Vanes to maintain contact with the interior peripheral wall of the Housing.

The Rotor shafts, which are in an eccentric position within the interior of the Housing and supported by the Housing's interior carrying walls, are provided with semi-metallic and nylon seals 21 to prevent gas leakage into the oil stream. A combination of “O” rings and nylon cap seals prevents external oil leakage, however dual sealing on both sides of the shaft can be incorporated. The Shaft's hollow core hole transports oil for lubrication and cooling. The Housings are provided with water coolant jackets, the fluid flow direction is from the Compressor towards the Afterburner. Shown in FIG. 2. The internal periphery of the Housing walls shown in FIG. 4 are provided with ports 12 for air induction and compressed air expulsion to port 14 for admission into the Combustor, in addition the holes 16 are drilled pressure balanced holes to equalize the gas pressure forces on top and bottom of the Vanes.

The Combustor shown in FIG. 2 and FIG. 3 comprises a Rotor 25 mounted in eccentric position within the interior of the Housing, and the rotor shaft supported by the Housing's two interior carrying walls 15 and 29. Said Rotor has four radial slots, through to the center hole, that are exposed to the stream of lubricating oil. Four slidable and movable Vanes 27 with half round knobs at the top, at opposite sides, aligned with the top surface, are guided in the hemispherical grooves in the interior side walls of the Housing 15 and 29. Semi-metallic and Nylon cap seals 31 are provided on both sides of the Rotor shaft to prevent hot gas leakage into the oil cavity. The housings 15 and 29 are also provided with water cooling jacket, while the Housings are secured by bolts 19 and nuts 9, to provide a strong and rigid connection. At the Housing's interface a circular spring-loaded metallic seal is installed and clamped to prevent hot gas leakage. As explained previously, the same construction approach as the Compressor with a full bore Housing and cover can be applied, while on the interior Housing wall periphery spark plugs 49 and fuel injectors 51 are installed. Shown in FIG. 1 and FIG. 3A. The Housing interior peripheral walls 15 and 29 are provided with gas outlet ports 16 to expel the exhaust gas and inlet ports 18 to introduce fresh compressed air from the Compressor for scavenge, combustion and work. Shown in FIG. 3.

The Vanes are provided with flat metallic contoured seals 33 to prevent high-pressure hot gas leakage between the chambers and oil seals 35 at the bottom end of the Vanes, and keep the hot gases separate from the oil cavity. The drilled holes 20 and 22 are additional cooling holes for the Rotor, while lubrication holes for the Vanes and Rotor are provided as by drilled holes 24, 26, 28 and 30. Shown in FIG. 2.

Although a circular bore for the Housings internal periphery is the simplest design, a specially contoured configuration as shown in FIG. 3A is also feasible to minimize exhaust gases entering the compression chamber. A different configuration of the Rotor is displayed in FIG. 3B, comprising a Cylindrical Rotor with dual Vanes, the advantage being that only oil seals 35 are required, since only one side of the Vane is exposed to hot gases. A configuration with dual balanced Vanes is shown in FIG. 3C. The advantage is that no oil seals or gas seals for the Vanes 39 are required, while lubrication is provided by means of drilled holes 28 and 30.

In FIG. 2 and FIG. 5 a cross-section of the Afterburner Unit is shown. It comprises of a cylindrical Rotor 41 with four through radial slots and a center hole for lubrication and cooling oil flow. In said slots four slidable and movable Vanes 43 with halfround knobs on opposite sides at the top end, aligned with the top surface, guided in the hemispherical grooves on both sides of the interior side walls of the housings 45 and 47, permanently in contact with the interior housing's peripheral wall, are inserted.

Semi-metallic and Nylon seals 49 are provided on both sides of the Rotor shaft to prevent hot gas from entering the oil cavities. Both Housings 45 and 47 are provided with water cooling jackets. At the interface joint a circular spring-loaded metallic seal 6 is clamped. The Housings 45 and 47 are secured by means of bolts 19 and nuts 9 to provide a sturdy connection.

The cylindrical Rotor 41 is mounted in an eccentric position within the interior of the Housing of the Afterburner. The Rotor shafts are supported by opposite carrying side-walls of the Housing 45 and 47. The interior wall periphery include inlet ports 32 and exhaust port 34, shown in FIG. 5, to admit the, partly cooled by scavenge air, combustion gases from the Combustor and to expel the lean re-burned gases to the atmosphere through exhaust the port 34.

The Vanes are only provided with oil seals since no compression occurs between the chambers, cooling holes and lubricating holes 36, 38, 40, and 42 are provided. Shown in FIG. 2. On said Housing's interior peripheral wall 45 and 47 Glow Plugs 53 and an optional Water Injector 55 are incorporated. Shown in FIG. 5.

FIG. 5A shows a semi oval shaped Housing configuration to create additional power by extending the Vane prior to expelling the exhaust gases.

FIG. 5B shows a dual balanced Vane configuration requiring no seals. The Vanes are cooled by injecting a water spray into the hot gases resulting in steam exhaust.

FIG. 6 and FIG. 7 show a typical cylindrical Rotor of a Combustor or Afterburner, with flat or rounded slot side surfaces.

FIG. 8 shows a one-piece construction of a Combustor Vane, which could be used for an Afterburner and Compressor.

FIG. 9 shows a Vane configuration with a separate half-knob pin construction 53 and 54, while 55 and 56 is a half-rounded sleeve and pin construction. These designs will allow the Pins and Knobs to slide and spin independently of the Vane in the interior Housing's hemispherical side-wall grooves to reduce friction. 

1. A Multi-Stage Modular Rotary Internal Combustion Engine of the Vane type, having a Compressor unit for inspiring air intake, charge and compressing said air. A Combustor unit receiving the charge from the Compressor unit for scavenge and compressing the air further, having a means for injecting fuel and igniting the air at a high degree of compression. The Combustor is driven by the expansion of the resulting combustion gases. The Afterburner Unit receives the combustion gases and scavenge air from the Combustor Unit and has the means for further burning the gases and is thereby driven through expansion and expulsion of the exhaust gases. The improvement comprises the Compressor unit having a larger displacement than the Combustor unit; the Afterburner unit having a displacement larger than the Compressor unit: Each Unit consists of a cylindrical Rotor and a shaft, splined at both ends, for rotation. The Rotor is mounted in an eccentric position within the interior of the Housing and supported by the Housing's interior carrying walls. Said shaft, provided with splines, has a hollow core to allow for lubrication and cooling oils. Said Rotor has a plurality of radial slots with flat or half-rounded end walls, defined therein, where radially extending, slidable and movable Vanes are inserted. Said Vanes' side surfaces contact the Housing interior side walls and the top surface of the Vane is in permanent contact with the surface of the interior peripheral wall of the Housing.
 2. Said Vanes with straight or half rounded end walls are provided with half-round knobs on opposite sides at the top end, aligned with the top surface, guided and slidable in hemispherical grooves at the top end of the Housing's interior side-walls, aligned with the Housing's interior peripheral wall. Thereby the Vanes are maintaining permanent contact with the interior walls of the Housing. The extension of the Vanes from the Rotor slots adjusts according to variances in the circumference of the Housing brought on by an increase in temperature. The interior shape of the Housing's peripheral wall could be any curvilinear configuration, such as circular, elliptical, oval with flat surface and torochoidal, and still maintain a permanent contact with the Vanes.
 3. Said Housing Construction, with Vanes provided with half round knobs, guided in hemispherical grooves, as described above, is applicable to any number of Internal Combustion Engines, Hydraulic or Pneumatic Rotary Motors or Pumping devices. 